The Advantages of Put-to-Light for Picking: Precision, Speed, and Flexibility

As pressure increases in e-commerce warehouses, with record delivery times becoming the norm, solutions are emerging to help businesses stay competitive. The Put-to-Light system is one such solution, designed to save valuable time in warehouses. But how does this system function? How does it optimise order preparation? And what errors can it help reduce? These questions are addressed in this article.

Put-to-Light is a light-guided order-picking assistance system that uses beaconing devices with LED lights at each shipping location, container, bin, or drawer. A light illuminates during the order-picking process to indicate the correct location and display the number of units to be placed on the system screen. Operators follow the lights to sort products quickly and accurately for dispatch in parcels.

Connected to the warehouse management software (WMS), the Put-to-Light system coordinates these light signals to guide operators step by step through their tasks. The logistics Put-to-Light system is particularly effective when multiple orders are prepared simultaneously for the same reference, streamlining the process and improving overall efficiency.

The primary benefit of the Put-to-Light system is its ability to significantly reduce errors in order fulfilment within the warehouse.

Firstly, the Put-to-Light system helps to reduce human errors caused by distractions, fatigue, or incorrect reference readings. By guiding operators to the correct locations with light signals, it ensures that each item is placed accurately. When integrated with the order management software, operators responsible for replenishing picking areas receive clear instructions. After scanning an item, the system automatically directs them to the correct location for placement.

Moreover, by facilitating at least partial automation of the order fulfilment process, the Put-to-Light system enhances precision, particularly in complex environments like e-commerce. The light signals enable operators to make fast, reliable decisions, which is crucial in high-volume order sorting, where minimising errors is essential.

The system also provides real-time feedback on stock levels through picking data, allowing for precise inventory management. This enhances the reliability of order preparation and reduces errors associated with manual stock-taking. These advantages contribute to a quick return on investment.

In addition to its exceptionally low error rate, Put-to-Light is straightforward to set up, and its intuitive light signals make it easily understandable for operators.

Order picking is the most time-consuming phase of warehouse operations, yet it is also the most critical. The good news is that the Put-to-Light system integrates seamlessly into existing processes, is highly scalable, and can be combined with conveyors or autonomous mobile robots (AMRs) to enhance efficiency, reduce errors, and minimise human intervention in decision-making during this crucial stage.

To optimise operations further, automating picking stations—acting as intermediaries between operators and handling robots (such as Skypod® robots)—proves to be a significant asset. These robots, equipped with bins and trays, work in conjunction with the warehouse execution system (WES). As a result, operators no longer need to travel long distances to deposit items; instead, the robots bring and remove the bins as orders progress. Once an item has been placed, the operator simply presses a button to send the bin to the next stage via a conveyor.

Moreover, the integration of the Put-to-Light system directly onto the picking station enables multiple orders to be processed simultaneously, further boosting productivity and minimising downtime.